VAT Photopolymerisation

Vat polymerisation uses a vat of liquid photopolymer resin, out of which the model is
constructed layer by layer. An ultraviolet (UV) light is used to cure or harden the resin where
required, whilst a platform moves the object being made downwards after each new layer is
cured. As the process uses liquid to form objects, there is no structural support from the
material during the build phase., unlike powder based methods, where support is given from the
unbound material. In this case, support structures will often need to be added. Resins are cured
using a process of photo polymerisation (Gibson et al., 2010) or UV light, where the light is
directed across the surface of the resin with the use of motor controlled mirrors (Grenda, 2009).
Where the resin comes in contact with the light, it cures or hardens.

1. The build platform is lowered from the top of the resin vat downwards by the layer
thickness.
2. A UV light cures the resin layer by layer. The platform continues to move downwards and
additional layers are built on top of the previous.
3. Some machines use a blade which moves between layers in order to provide a smooth
resin base to build the next layer on.
4. After completion, the vat is drained of resin and the object removed.

Advantages:

 High level of accuracy and good finish

 Relatively quick process
 Typically large build areas: objet 1000: 1000 x 800 x 500 and max model weight of 200 kg

Disadvantages:
 Relatively expensive
 Lengthly post processing time and reomval from resin
 Limited material use of photo-resins
 Often requires support structures and post curing for parts to be strong enough for structural
use
 Powder Bed Fusion
The Powder Bed Fusion process includes the following commonly used printing
techniques: Direct metal laser sintering (DMLS), Electron beam melting (EBM), Selective
heat sintering (SHS), Selective laser melting (SLM) and Selective laser sintering
(SLS).Powder bed fusion (PBF) methods use either a laser or electron beam to melt and
fuse material powder together. Electron beam melting (EBM), methods require a vacuum
but can be used with metals and alloys in the creation of functional parts. All PBF processes
involve the spreading of the powder material over previous layers. There are different
mechanisms to enable this, including a roller or a blade. A hopper or a reservoir below of
aside the bed provides fresh material supply. Direct metal laser sintering (DMLS) is the
same as SLS, but with the use of metals and not plastics. The process sinters the powder,
layer by layer. Selective Heat Sintering differs from other processes by way of using a
heated thermal print head to fuse powder material together. As before, layers are added
with a roller in between fusion of layers. A platform lowers the model accordingly.

1. A layer, typically 0.1mm thick of material is spread over the build platform.
2. A laser fuses the first layer or first cross section of the model.
3. A new layer of powder is spread across the previous layer using a roller.
4. Further layers or cross sections are fused and added.
5. The process repeats until the entire model is created. Loose, unfused powder is remains in
position but is removed during post processing.

Advantages:

 Relatively inexpensive
 Suitable for visual models and prototypes
 (SHS) Ability to integrate technology into small scale, office sized machine
 Powder acts as an integrated support structure
 Large range of material options

Disadvantages:
 Relatively slow speed (SHS)
 Lack of structural properties in materials
 Size limitations
 High power usage
 Material Extrusion
Fuse deposition modelling (FDM) is a common material extrusion process and is
trademarked by the company Stratasys. Material is drawn through a nozzle, where it is
heated and is then deposited layer by layer. The nozzle can move horizontally and a
platform moves up and down vertically after each new layer is deposited. It is a commonly
used technique used on many inexpensive, domestic and hobby 3D printers.The process
has many factors that influence the final model quality but has great potential and viability
when these factors are controlled successfully. Whilst FDM is similar to all other 3D printing
processes, as it builds layer by layer, it varies in the fact that material is added through a
nozzle under constant pressure and in a continuous stream. This pressure must be kept
steady and at a constant speed to enable accurate results (Gibson et al., 2010). Material
layers can be bonded by temperature control or through the use of chemical agents.
Material is often added to the machine in spool form.

1. First layer is built as nozzle deposits material where required onto the cross sectional area of
first object slice.
2. The following layers are added on top of previous layers.
3. Layers are fused together upon deposition as the material is in a melted state.

Advantages:

 Widespread and inexpensive process

 ABS plastic can be used, which has good structural properties and is easily accessible

Disadvantages:

 The nozzle radius limits and reduces the final quality

 Accuracy and speed are low when compared to other processes and accuracy of the final model is limited
to material nozzle thickness
 Constant pressure of material is required in order to increase quality of finish
 Material Jetting
Material jetting creates objects in a similar method to a two dimensional ink jet printer.
Material is jetted onto a build platform using either a continuous or Drop on Demand (DOD)
approach.

Material is jetted onto the build surface or platform, where it solidifies and the model is built
layer by layer. Material is deposited from a nozzle which moves horizontally across the build
platform. Machines vary in complexity and in their methods of controlling the deposition of
material. The material layers are then cured or hardened using ultraviolet (UV) light.

As material must be deposited in drops, the number of materials available to use is limited.
Polymers and waxes are suitable and commonly used materials, due to their viscous nature
and ability to form drops.

1. The print head is positioned above build platform.

2. Droplets of material are deposited from the print head onto surface where required, using either
thermal or piezoelectric method.
3. Droplets of material solidify and make up the first layer.
4. Further layers are built up as before on top of the previous.
5. Layers are allowed to cool and harden or are cured by UV light. Post processing includes
removal of support material.

Advantages:

 The process benefits from a high accuracy of deposition of droplets and therefore low waste
 The process allows for multiple material parts and colours under one process

Disadvantages:

 Support material is often required

 A high accuracy can be achieved but materials are limited and only polymers and waxes can be
used
 Sheet Lamination
Sheet lamination processes include ultrasonic additive manufacturing (UAM) and laminated
object manufacturing (LOM). The Ultrasonic Additive Manufacturing process uses sheets or
ribbons of metal, which are bound together using ultrasonic welding. The process does
require additional cnc machining and removal of the unbound metal, often during the
welding process. Laminated object manufacturing (LOM) uses a similar layer by layer
approach but uses paper as material and adhesive instead of welding. The LOM process
uses a cross hatching method during the printing process to allow for easy removal post
build. Laminated objects are often used for aesthetic and visual models and are not suitable
for structural use. UAM uses metals and includes aluminium, copper, stainless steel and
titanium (Ultrasonic Additive Manufacturing Overview, 2014). The process is low
temperature and allows for internal geometries to be created. The process can bond
different materials and requires relatively little energy, as the metal is not melted.
1. The material is positioned in place on the cutting bed.
2. The material is bonded in place, over the previous layer, using the adhesive.
3. The required shape is then cut from the layer, by laser or knife.
4. The next layer is added.
5. Steps two and three can be reversed and alternatively, the material can be cut before being
positioned and bonded.

Advantages:

 Benefits include speed, low cost, ease of material handling, but the strength and integrity of
models is reliant on the adhesive used (Krar and Gill, 203)
 Cutting can be very fast due to the cutting route only being that of the shape outline, not the
entire cross sectional area

Disadvantages:
 Finishes can vary depending on paper or plastic material but may require post processing to
achieve desired effect
 Limited material use
 Fusion processes require more research to further advance the process into a more mainstream
positioning
 Directed Energy Deposition
A typical DED machine consists of a nozzle mounted on a multi axis arm, which deposits
melted material onto the specified surface, where it solidifies. The process is similar in
principle to material extrusion, but the nozzle can move in multiple directions and is not
fixed to a specific axis. The material, which can be deposited from any angle due to 4 and 5
axis machines, is melted upon deposition with a laser or electron beam. The process can be
used with polymers, ceramics but is typically used with metals, in the form of either powder
or wire.

Sequence of operation-:

1. A4 or 5 axis arm with nozzle moves around a fixed object.

2. Material is deposited from the nozzle onto existing surfaces of the object.

3. Material is either provided in wire or powder form.

4. Material is melted using a laser, electron beam or plasma arc upon deposition.

5. Further material is added layer by layer and solidifies, creating or repairing new material

features on the existing object.

Advantages:

 Ability to control the grain structure to a high degree, which lends the process to repair work of high
quality, functional parts
 A balance is needed between surface quality and speed, although with repair applications, speed can
often be sacrificed for a high accuracy and a pre- determined microstructure

Disadvantages:

 Finishes can vary depending on paper or plastic material but may require post processing to achieve
desired effect
 Limited material use
 Fusion processes require more research to further advance the process into a more mainstream
positioning